Catalyst for the synthesis of CF3I and CF3CF2I

ABSTRACT

A process for the preparation of a fluoroiodoalkane compound represented by the formula: CF 3 (CF 2 ) n —Y, wherein n is 0 or 1. The process includes contacting A, B and C. A is represented by the formula: CF 3 (CF 2 ) n —Y, wherein n is 0 or 1, and Y is selected from the group consisting of: H, Cl, Br, and COOH. B is a source of iodine, and C is a catalyst containing elements with d 1 s 1  configuration and lanthanide elements. The process occurs at a temperature, and for a contact time, sufficient to produce the fluoroiodoalkane compound.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present disclosure is related to the synthesis of CF₃I and CF₃CF₂I. More particularly, the present disclosure is related to a family of catalysts used in the synthesis of CF₃I and CF₃CF₂I.

2. Description of Related Art

Trifluoroiodomethane (CF₃I) and pentafluoroiodoethane (C₂F₅I) are useful chemicals. CF₃I is a potential fire extinguisher substituting for trifluorobromomethane, a fluorine-containing intermediate compound for introducing a trifluoromethyl group in producing surfactants, chemicals and pharmaceuticals, and a refrigerant with low global warming potential when blended together with some hydrofluorocarbons. C₂F₅I is used as a synthesis intermediate in many applications related to the field of fluorinated surface-active substances, and more particularly, as bases for fire-extinguishing formulations, as hydrophobic and olephobic finishes on various substrates, and as a medical agent.

Both batch and continuous processes have been developed for the production of trifluoroiodomethane. For batch process, it has been shown that trifluoroiodomethane can be prepared by reacting trifluoroacetic acid or its derivative with iodine. However, this process required strict control of reaction conditions and moisture level in source materials, and moreover, expensive silver trifluoroacetate had to be used in order to achieve a high yield of trifluoroiodomethane.

Alternatively, trifluoroiodomethane can be made through continuous vapor-phase reaction. However, the catalyst families developed so far for known processes are limited to supported salts of alkali and alkaline earth metals and Cul. These catalysts suffered from rapid deactivation due to carbon formation during reaction and/or the loss and sintering of active components in catalysts.

Accordingly, there is a need to develop alternative catalyst systems and processes that overcome, alleviate, and/or mitigate one or more of the aforementioned and other deleterious effects of the prior art catalysts and processes.

SUMMARY OF THE INVENTION

The present disclosure provides a process for the preparation of a fluoroiodoalkane compound represented by the formula: CF₃(CF₂)_(n)—Y, wherein n is 0 or 1. The process includes the step of contacting A, B and C, wherein A is represented by the formula: CF₃(CF₂)_(n)—Y, wherein n is 0 or 1, and Y is selected from the group consisting of: H, Cl, Br, and COOH. B is a source of iodine, and C is a catalyst containing elements with d¹s¹ configuration and lanthanide elements. The process occurs at a temperature, and for a contact time, sufficient to produce the fluoroiodoalkane compound.

It is an object of the present disclosure to provide a process for producing trifluoroiodomethane (CF₃I) and pentafluoroiodoethane (C₂F₅I) using elements with a d¹s¹ configuration or lanthanide elements as a catalyst.

It is another object of the present disclosure to provide a process for producing trifluoroiodomethane (CF₃I) and pentafluoroiodoethane (C₂F₅I) using transition metals, noble metals, or rare earth metals as promoters for the activity of the catalysts of the present disclosure.

The above-described and other features and advantages of the present disclosure will be appreciated and understood by those skilled in the art from the following detailed description and appended claims.

DETAILED DESCRIPTION OF THE INVENTION

The present disclosure provides catalysts used in a process to prepare a fluoroiodoalkane compound represented by the formula: CF₃(CF₂)_(n)—I, where n is 0 or 1, from a compound represented by the formula: CF₃(CF₂)_(n)—Y, wherein Y is selected from H, Cl, Br, and COOH, and n is 0 or 1. The process can be executed in the presence of a source of iodine (I₂, Hl, ICl, IF₅, Cl₄, etc.), and in the presence or absence of a source of oxygen (O₂, air, ozone, N₂O, H₂O₂, etc.).

In some embodiments, catalysts for this process contain elements with d¹s¹ configuration and/or lanthanide elements, including but not limited to, Scandium (Sc), Yttrium (Y), Lanthanum (La), Cerium (Ce), Praseodymium (Pr), Neodymium (Nd), Promethium (Pm), Samarium (Sm), Europium (Eu), Gadolinium (Gd), Terbium (Tb), Dysprosium (Dy), Holmium (Ho), Erbium (Er), Thulium (Tm), Ytterbium (Yb) and Lutetium (Lu), in any existing forms of any existing precursors.

Catalysts can be prepared by supporting each of the elements or a mixture thereof, on a support, preferably activated carbon, or used directly as bulk (unsupported). The amount of these elements ranges from 0.001% to 100% by weight of the entire catalyst, and all the subranges therebetween. Precursors of these elements can be oxide, nitrate, halide, carbonate, bicarbonate, sulfate and phosphate, or other existing salts and compounds.

Catalysts can be used by themselves or can be promoted/modified by transition metal (including noble metal) or main group elements. Transition metal promoters/modifier includes, but is not limited to, the following elements: Ti, V, Cr, Mn, Co, Ni, Zn, Zr, Nb, Mo, Ru, Rh, Pd, W, Re, Pt, Ag, Ce, Pr, etc. Any combination of these elements, or a salt or other form of one or a combination of these elements is included in the list of promoters/modifiers. Promoters/modifier of main group elements includes, but not limited to, the following: alkali metal (Li, Na, K, Rb and Cs), alkaline earth metal (Be, Mg, Ca, Sr and Ba), Al, P, Ga, In, Sn, Sb, Tl, Bi, etc, and any combination of these elements. The promoter/modifier can be a single element in any existing forms of any existing precursors (i.e., a salt), or a combination of any existing forms of any existing precursors of those elements.

In some embodiments, when alkali and/or alkaline earth metals are used as promoter/modifier, the atomic ratio of elements with d¹s¹ configuration and lanthanide elements to these metals is greater than 1, that is, only small amounts of alkali and/or alkali earth metals are used as a promoter. For other promoter/modifier, the atomic ratio of elements with d¹s¹ configuration and lanthanide to promoters/modifiers in a catalyst ranges from 0.00001 to 100000, more preferably from 0.0001 to 10000. The above ranges provided for the atomic ratio of elements include all subranges that fall within the parameters of the ranges identified.

The as-prepared promoted catalysts can be calcined in an inert gas such as nitrogen at 100-750° C., more preferably at 300-600° C., and all subranges therebetween.

Before reaction, the catalysts can be further treated in an inert gas, hydrogen, HF, HCl, Hl, F₂, Cl₂, CF₃H, I₂, air, oxygen, or a mixture thereof, at, above, or below the particular reaction temperature in which they will be used. The reaction temperature ranges can be from about 100° C. to about 750° C., and all temperatures therebetween. More preferably, the reaction temperature ranges from about 300° C. to about 600° C., and all temperatures therebetween.

In the practice of the process of the present disclosure, the reaction can be carried out at a temperature from about 100° C. to about 750° C., at a pressure from about 0.001 atm to about 100 atm, and for a contact time from about 0.001 sec to about 300 hours. The contact time is defined as volume of catalyst divided by the volumetric velocity of all feeds. Also, the reaction can be carried out under pressures and a contact duration that fall within those ranges.

The process can be either a batch process or it can be a continuous process. Also, the reactor type can be a fixed bed reactor or a moving bed reactor, such as fluidized bed reactor, rotary reactor, rising bed reactor, or a combination thereof.

The reactor can optionally include a diluent, including an inert gas such as nitrogen, CO, CO₂, water, an organic solvent, or a mixture thereof.

The process can further include one or more of the following steps: passing the fluoroiodoalkane, which can be trifluoromethyl iodide or pentafluoroethyl iodide, through a scrubber containing an aqueous alkali solution. The process can also include passing the fluoroiodoalkane through a scrubber containing a drying agent, followed by cooling at a temperature below the boiling temperature of the fluoroiodoalkane to condense. The process can also include a step of isolating the fluoroiodoalkane from the reaction mixture in essentially a pure form.

The following non-limiting examples are illustrative of the various embodiments of the present disclosure. It is within the ability of a person of ordinary skill in the art to select other variables from amongst the many known in the art without departing from the scope of the present disclosure. Accordingly, these examples shall serve to further illustrate the present disclosure, not to limit it.

EXAMPLE 1 Catalyst Preparation

Preparation of carbon supported lanthanum oxide or salt (La₂O₃/C) catalysts: Designated amount of La(NO₃)₃ was dissolved in deionized water (the amount of water was calculated from the pore volume of a support). After La(NO₃)₃ was dissolved completely, designated amount of activated carbon (pre-dried at 100-120° C. for 12 hrs) was slowly poured into the solution, or vice versa. The paste was stirred continuously to achieve homogeneous impregnation and then was put in the hood overnight to allow adequate impregnation. Subsequently, the impregnated sample was dried in an oven at 100-120° C. for 12 hrs and calcined at 450-550° C. for 4 hrs in flowing nitrogen.

Preparation of promoted La₂O₃/C catalysts: Designated amount of La(NO₃)₃ and designated amount of precursor of a promoter were dissolved in desired amount of deionized water. After all salts were dissolved completely, designated amount of activated carbon (pre-dried at 100-120° C. for 12 hrs) was slowly poured into the solution, or vice versa. The paste was stirred continuously to achieve homogeneous impregnation and then was put in the hood overnight to allow adequate impregnation. Subsequently, the impregnated sample was dried in an oven at 100-120° C. for 12 hrs and calcined at 450-550° C. for 4 hrs in flowing nitrogen. In case of step-wise impregnation, a salt of a promoter was first impregnated on activated carbon overnight. After drying/calcination, La(NO₃)₃ was impregnated on activated carbon, followed by drying and calcination.

The activated carbon support used in this disclosure was pelletized Shirasagi C2X 4/6-2 from Japan EnviroChemicals, Ltd, although any support known in the art could be used. Pelletized Shirasagi C2X 4/6-2 is highly purified, with a surface area above 1000 m²/g and an average pore diameter 23 Å.

EXAMPLE 2

Reactivity of carbon supported catalysts containing elements with d¹s¹ configuration—Table 1 lists the activity and selectivity of some activated carbon supported catalysts which contain elements with d¹s¹ configurations, such as Scandium (Sc), Yttrium (Y), and Lanthanum (La), after 20 hrs on stream at 500° C. For 5% Sc₂O₃/C, it began to show activity after 7 hours on stream. The CF₃H conversion and CF₃I selectivity of 5% Sc₂O₃/C were 6.3% and 65.5%, respectively, after 10 hrs on steam. The catalyst remained stable after 20 hrs on stream, with 6.2% CF₃H conversion, 65.4% CF₃I selectivity and 1.6% CF₃CF₂I selectivity. The induction period was 12 hrs for 5% Y₂O₃/C, which exhibited 4.6% CF₃H conversion and 65.5% CF₃I selectivity after reacted for 20 hrs. For 5% La₂O₃/C, its induction period was 8 hrs. At 10 hrs of reaction time, it showed 8.3% CF₃H conversion and 65.0% CF₃I selectivity. Its activity increased to about 10% after 12 hrs on stream and then remained stable thereafter. After reacted for 20 hrs, the CF₃H conversion, CF₃I selectivity and CF₃CF₂I selectivity of 5% La₂O₃/C were 10.3%, 64.9% and 2.5%, respectively.

TABLE 1 Reactivity of carbon supported catalysts containing elements with d¹s¹ configuration. Reaction condition: 500° C., I₂/CF₃H = 0.33, O₂/CF₃H = 0.1, contact time: 20 s. Reaction time: 20 hr. CF₃H CF₃I CF₃CF₂I Catalyst conversion (%) selectivity (%) selectivity (%) 5% Sc₂O₃/C 6.2 65.4 1.6 5% Y₂O₃/C 4.6 65.5 1.5 5% La₂O₃/C 10.3 64.9 2.5

EXAMPLE 3

Reactivity of carbon supported catalysts containing lanthanide (rare-earth) elements. The reactivity of carbon supported catalysts containing various lanthanide (rare-earth) elements are listed in Table 2. The data given here was obtained after 10 hrs on stream. The catalysts contained 10 wt. % of rare earth metal oxide were tested at 500° C., and they showed about 6-12% CF₃H conversion, about 65% CF₃I selectivity and about 2-3% CF₃CF₂I selectivity. 10% La₂O₃/C exhibited 11.9% CF₃H conversion, which was slightly greater than the other catalysts. 5% Eu₂O₃/C and 5% Tm₂O₃/C were tested at 550° C. in order to reduce the induction period. The CF₃H conversion, CF₃I selectivity and CF₃CF₂I selectivity for 5% Eu₂O₃/C were 34.0%, 57.7% and 4.8%, respectively, and those for 5% Tm₂O₃/C were 34.9%, 60.4% and 3.7%, respectively.

TABLE 2 Reactivity of carbon supported catalysts containing lanthanide (rare-earth) elements. Reaction condition: 500 or 550° C., I₂/CF₃H = 0.33, O₂/CF₃H = 0.1, contact time: 20 s. Reaction time: 10 hr. Reaction CF₃H CF₃I temp. conversion selectivity CF₃CF₂I Catalyst (° C.) (%) (%) selectivity (%) 10% La₂O₃/C 500 11.9 65.1 2.3 10% Pr₂O₃/C 500 10.7 64.6 2.7 10% Sm₂O₃/C 500 9.7 64.9 2.4 10% Er₂O₃/C 500 7.6 65.3 2.0 10% Yb₂O₃/C 500 6.2 65.6 1.6  5% Eu₂O₃/C 550 34.0 57.7 4.8  5% Tm₂O₃/C 550 34.9 60.4 3.7

EXAMPLE 4

Effect of La₂O₃ loading on the reactivity of La₂O₃/C. The effect of La₂O₃ loading on the catalyst activity and selectivity was investigated and the data is listed in Table 3. When there was no lanthanum oxide, the activated carbon support itself was not active at 500° C. Only trace amount (0.06%) of CF₃H was converted into CF₃I and some other products. However, when only 2 wt. % La₂O₃ was supported on carbon, the catalyst gave 12.8% CF₃H conversion and 64.8% CF₃I selectivity. When the La₂O₃ loading was increased to 5 wt. %, the catalyst activity exhibited slightly lower activity (8.3% CF₃H conversion) after 10 hrs on stream. With increasing La₂O₃ loading from 5 wt. % to 20 wt. %, the CF₃H conversion increased monotonically from 8.3% to 12.9%, with slightly drop of CF₃I selectivity from about 65% to about 62%. The CF₃CF₂I selectivity of these La₂O₃/C catalysts was between 2% to 4%.

TABLE 3 Effect of La₂O₃ loading on the reactivity of La₂O₃/C. Reaction condition: 500° C., I₂/CF₃H = 0.33, O₂/CF₃H = 0.1, contact time: 20 s. Reaction time: 10 hr. CF₃CF₂I La₂O₃ CF₃H CF₃I selectivity loading (wt. %) conversion (%) selectivity (%) (%) 0 (carbon only) 0.06 58.4 0 2.0 12.8 64.8 2.5 5.0 8.3 65.0 2.4 10.0  11.9 65.1 2.3 20.0  12.9 62.0 3.5

EXAMPLE 5

Effect of reaction conditions. The reactivity of 5% La₂O₃/C was investigated under various reaction conditions. From Table 4, it can be seen that the catalyst activity increased significantly from 8.3% to 39.5% when reaction temperature was elevated from 500° C. to 550° C., with slightly decrease in CF₃I selectivity from 65% to 53.6% and slightly increase in CF₃CF₂I selectivity from 2.4% to 5.0%. By increasing the contact time from 19 s to 38 s at 550° C., CF₃H conversion of the catalyst was further increased to 48.3%, with 53.3% CF₃I selectivity and 3.2% CF₃CF₂I selectivity. These data suggested that the catalyst activity was tunable by varying reaction parameters such as reaction temperature and contact time.

TABLE 4 Effect of reaction conditions on the reactivity of 5% La₂O₃/C. Reaction time: I₂/CF₃H = 0.33, O₂/CF₃H = 0.1. Reaction time: 10 hr. Contact CF₃H CF₃I Reaction time conversion selectivity CF₃CF₂I temp. (° C.) (s) (%) (%) selectivity (%) 500 20 8.3 65.0 2.4 550 19 39.5 53.6 5.0 550 38 48.3 53.3 3.2

EXAMPLE 6

Effect of promoters/additives on the activity of La₂O₃/C. Various promoters/additives can modify the reactivity of La₂O₃/C catalyst. Table 4 offers some examples concerning the effect of platinum and potassium. When 1 wt. % Pt was added to 5% La₂O₃/C, the catalyst showed longer induction period than that of platinum-free catalyst. Pt—La₂O₃/C catalyst gained activity after run for 12 hrs, and its CF₃H conversion and CF₃I selectivity were 9.4% and 62.6%, respectively, after run for 15 hrs (Table 5).

Small amounts of alkali metal salts, such as potassium nitrate, were also added to 5% La₂O₃/C and 10% La₂O₃/C. The atomic ratio of lanthanum to potassium (La/K) was controlled to be greater than 1 (>1). As can be seen from Table 5, catalyst activity was significantly increased upon addition of small amount of potassium nitrate. The 0.2% K-5% La₂O₃/C gave 22.3% CF₃H conversion and 60.9% CF₃I selectivity. With increasing potassium loading, the catalyst activity further increased for both K-5% La₂O₃/C and K-10% La₂O₃/C. The induction period was reduced by the addition of potassium salt, but the CF₃CF₂I selectivity was higher in the presence of potassium (about 5-6%).

TABLE 5 Reactivity of Pt—5% La₂O₃/C, K—5% La₂O₃/C, and K—10% La₂O₃/C. Reaction condition: 500° C., I₂/CF₃H = 0.33, O₂/CF₃H = 0.1, contact time: 20 s. Reaction time: 10 hr. La/K CF₃H CF₃I CF₃CF₂I atomic conversion selectivity selectivity Catalyst ratio (%) (%) (%) 1.0% Pt—5% La₂O₃/C /  9.4 62.6 1.7 (15 hrs) (15 hrs) (15 hrs) 0.2% K—5% La₂O₃/C 6.0 22.3 60.9 5.7 0.5% K—5% La₂O₃/C 2.4 29.3 62.5 4.6 1.0% K—5% La₂O₃/C 1.2 34.9 61.5 5.5 1.0% K—10% La₂O₃/C 2.4 40.4 58.9 6.2 2.0% K—10% La₂O₃/C 1.2 43.6 60.3 5.8

From the above-mentioned examples, it is obvious that catalysts containing elements with d¹s¹ configurations and lanthanide are active for making CF₃I and CF₃CF₂I. By varying reaction conditions and promoting with other elements, the catalyst activity was further enhanced.

It should also be noted that the terms “first”, “second”, “third”, and the like may be used herein to modify various elements or steps. These modifiers do not imply a spatial, sequential, or hierarchical order to the modified elements unless specifically stated.

While the present disclosure has been described with reference to one or more exemplary embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the present disclosure. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the disclosure without departing from the scope thereof. Therefore, it is intended that the present disclosure not be limited to the particular embodiment(s) disclosed as the best mode contemplated, but that the disclosure will include all embodiments falling within the scope of the appended claims. 

1. A process for the preparation of a fluoroiodoalkane compound represented by the formula: CF_(3(CF) ₂₎ _(n-1), wherein n is 0 or 1, comprising: contacting A, B and C, wherein A is represented by the formula: CF₃(CF₂)_(n-Y), wherein n is 0 or 1, and Y is selected from the group consisting of: H, Cl, Br, and COOH, and B is a source of iodine, and C is a catalyst selected from the group consisting of Sc, Y, La, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, Lu, a mixture thereof, and any salts thereof, and wherein said process occurs at a temperature and for a contact time sufficient to produce said fluoroiodoalkane compound.
 2. The process of claim 1, wherein said contacting is carried out in the presence of a catalyst modifier for said catalyst, and wherein said catalyst modifier comprises at least one element selected from the group consisting of: a transition metal element, a main group element, any salts thereof, and any combinations thereof.
 3. The process of claim 2, wherein the contacting is carried out in the presence of a diluent and in the presence of a source of oxygen.
 4. The process of claim 2, wherein said catalyst is supported.
 5. The process of claim 2, wherein said catalyst is unsupported.
 6. (canceled)
 7. The process of claim 2, wherein said catalyst modifier is a transition metal element selected from the group consisting of: Ti, V, Cr, Mn, Fe, Go, Ni, Cu, Zn, Zr, Nb, Mo, Tc, Ru, Rh, Pd, Ag, Cd, Hf, Ta, W, Re, Os, Ir, Pt, Au, Hg, a mixture thereof, and any salts thereof.
 8. The process of claim 2, wherein said catalyst modifier is a main group element other than an alkali and alkaline metal element selected from the group consisting of: B, Al, Ga, In, TI, Ge, Sn, Sb, Bi, a mixture thereof, and any salts thereof.
 9. The process of claim 2, wherein said catalyst modifier is an alkali and alkaline metal element selected from the group consisting of: Li, Na, K, Rb, Cs, Be, Mg, Ca, Sr, Ba, a mixture thereof, and any salts thereof, and wherein the atomic ratio of elements with d¹ s¹ configuration and lanthanide elements to alkali and alkaline earth metals is greater than
 1. 10. The process of claim 1, wherein said fluoroiodoalkane is selected from the group consisting of: trifluoroiodomethane, pentafluoroiodoethane, and a mixture thereof.
 11. The process of claim 1, wherein said compound represented by the formula CF₃(CF₂)_(n-Y) is selected from the group consisting of: CF₃H, CF₃CF₂H, CF₃COOH, CF₃CI, CF₃Br, and a mixture thereof.
 12. The process of claim 1, wherein said catalyst is pretreated at a temperature above or below the reaction temperature using a substance selected from the group consisting of: nitrogen, helium, argon, hydrogen, HF, HCl, HI, F_(2,) Cl_(2,) CF₃H, I₁₂, air, oxygen, and a mixture thereof.
 13. The process of claim 1, wherein said source of iodine is a compound selected from the group consisting of: I₁₂, HI, ICI, IF_(5,) Cl_(4,) and a mixture thereof.
 14. The process of claim 3, wherein said source of oxygen is a compound selected from the group consisting of: O₂, air, O₃, N_(20,) H₂O_(2,) and a mixture thereof.
 15. The process of claim 1, wherein said step of contacting is carried out at a temperature from about 100° C. up to about 750° C.
 16. The process of claim 1, wherein said step of contacting is carried out at a pressure from about 0.001 atm to about 100 atm.
 17. The process of claim 1, wherein said step of contacting is carried for a contact time from about 0.001 sec to about 300 hours.
 18. The process of claim 1, wherein the process is a batch or continuous process.
 19. The process of claim 1, wherein contacting is carried out in a fixed bed reactor, a moving bed reactor, a fluidized bed reactor, a rotary kiln reactor, a rising bed reactor, or a combination thereof.
 20. The process of claim 2, wherein said diluent is selected from the group consisting of: nitrogen, helium, argon, CO, CO_(2,) water, organic solvent, and a mixture thereof.
 21. The process of claim 1, further comprising the step of passing the fluoroiodoalkane through a scrubber containing an aqueous alkali solution.
 22. The process of claim 1, further comprising the step of passing the fluoroiodoalkane through a scrubber containing a drying agent.
 23. The process of claim 1, further comprising the step of cooling at a temperature below the boiling temperature of the fluoroiodoalkane to condense.
 24. The process of claim 1, further comprising the step of isolating the fluoroiodoalkane from the reaction mixture in essentially pure form. 